Compressors

Air-End Overhaul

2010-11-03T05:54:00.000-07:00

A 2-days intensive, practical based Twin Screw Air Compressor's Air-End Overhaul Course.

Special Offer

Members pay only RM500.00 per person, per course.

A manual will be provided.

"Blow Hole"

Typical design limitations in a Rotary Twin Screw Air Compressors.

Rotary Screw Air Compressor Overhaul !

2010-04-17T02:34:00.001-07:00

Ingersoll Rand EP100 air compressor [with 86 kw main motor] overhaul;
Main Motor and Air End;
Penang, Malaysia, on the 15th April 2010

The Air End to be overhaul; awaiting dismantle
Note the check valve [ Non return valve ] with the arrow of flow.

The male rotor DE bearing's outer race.

Both the bearings of the rotors at the front end, where the gear box is.

Male rotor shaft on the left,
Note !
The worn out male rotor drive bearing

The rotors waiting to be push out from their cocoon [Compressor case / Housing ].

The Air End rotors' after the NU type of bearings being remove.

The Air End rotors' after the NU type of bearings being remove.
Both male and female rotors.

The pressure end side, note the tapered bearings.

The Air End cover, the high pressure side.
There is overheating at this end.

Shaft seal to prevent compressor oil [ Coolant ] from leak into the motor windings

The shaft seal is install here. [ inside ]

The dismantling of the Air Compressor main motor.

Non drive end [ NDE ] side of the main motor.
with it's cover on the cement floor.

Showing the stator and rotor shaft with motor shaft bearing.

NDE motor cover

Drive end [ DE ] side of the main motor

The DE bearing cover,

The DE bearing cover, front is the gear box side.

The motor after dismantle, prepare to clean by air jet.
Lot of white from the rubber glove manufacturing facilities.

Prepare the motor coil for varnishing.

After re-varnishing the Stator Coil.

Testimonies

2010-04-17T02:19:00.000-07:00

Testimonial from Institute Latihan Perindustrian, Jitra, Kedah
for conducting a one day workshop on Basic Air Compressor course to teachers and students of the Institute.

From Almig Compressor of Germany.
The number Air Compressor Company in Germany,
The hot bed of compressor manufacturer and air end manufacturing.

Rotary Screw Air Compressor Overhaul !

2010-04-17T02:02:00.001-07:00

Rotary Twin Screw Air Compressor Overhaul;
14th April 2010
Penang, Malaysia.
Model: CompAir Broomwade N6090, imported version [ not sold locally ]

Front showing the drive coupling, behind the shaft is the gear box.

Pinion shaft of drive gear, gear box housing

Compressor case, note the size;
The bigger size hole is for male drive rotor.
The smaller size on the left is the female rotor, driven.

The end plate, note the wear on the surface on the bigger rotor.
Cause by some foreign metal particles.

Gear case housing

Driven rotor, that is the female rotor.

Drive rotor, this case is the male rotor.
The gear on the floor is mounted in the gear box to the drive shaft of the main motor, this gear will drive the smaller size gear install on one end of the male rotor shaft.

Can you afford to give away money?

2010-02-24T05:34:00.000-08:00

Can you afford to give away money?

We will show you how to save money:

on the production of compressed air

Each compressed air station offers an enormous potential for conserving energy,

for example in the following areas:

Compressor capacity utilisation
Modern compressor technologies, e.g. speed control
Modern control systems
Efficient compressed air treatment, not too much, not too little
Heat utilisation, what is it "worth"?
Leaks: find/reduce them
Pressure losses: localise/prevent them
Correct component dimensions
(piping, tanks, ...)
etc., etc.

During the one-day seminar for operators and planners of compressed air stations

we will show you

" Possible ways of producing compressed air at a reasonable price "

Practically oriented, with case studies, we make interesting suggestions, give tips and assistance regarding the correct way to handle the energy source, compressed air.

We are convinced that the costs of producing compressed air can be effectively reduced by means of minimal measures also in your case.

Are you interested?

Take Action Now !

We would be delighted if you would contact us.

Air End Overhaul --- QSI1000

2010-02-17T00:49:00.000-08:00

Air End Overhaul:
Completed and test run in February 2010, just before Chinese Lunar New Year.

Male rotor on shaft stand, ready to repair.

You are right, Wong; too much self-discipline will discourage your playful, wandering imagination. It'll snuff out the flames of inspiration and creativity. And it'll weigh you down with routines and logic. It simply isn't "spiritual."

But, then, neither is too little.

Another view of the same Male rotor;
QSI 1000

" To swear off making mistakes is very easy. All you have to do is swear off having ideas "

Note:
The worn out Drive end bearing inner cone!

"The reality of life is that your perceptions -- Right or Wrong -- influence everything else you do. When you get a proper perspective of your perceptions, you may be surprised how many other things fall into place."

Another view of the male rotor

Focus on Your Top Priorities -- First...

The Failed Air End Bearings.

"My philosophy of life is that if we make up our mind what we are going to make of our lives, then work hard toward that goal, we never lose -- somehow we win out." ~ Ronald Reagan

The QSI 1000, Air End Housing (Compressor Case?)

" Another question for you - do you know what the difference between interested vs committed in achieving your life's goals and dreams? "

The far end of the compression,
this is where the clearance is set, between rotor's end and housing.

Another view of the same;

The female rotor

Another view of the female rotor

" Always aim at complete harmony of thought and
word and deed. Always aim at purifying your
thoughts and everything will be well ."

Energy Saving in Motor Start-up

2009-11-01T18:04:00.000-08:00

Energy Saving in Compressor's Motor Start-up

Potential Energy Saving in Speed Controlled Compressor

Example:

What is Speed Control?

These Compressors are usually Direct Coupled, Direct Drive, meaning the Main Motor is directly driving the Rotor [usually Male Rotor].

Is a Electronically based control, where the speed [rpm] of Main Drive Motor is varied to adjust the free air delivery [FAD] to change in Plant air usage.

* If Demand Increase!
Motor Speed is increased, and therefore, the speed of the rotors is increased -----> free air delivery increases.

* If Demand Decrease!
Motor Speed is reduced, and therefore, the speed of the rotors is reduced -----> free air delivery decreases.

What If

2009-10-26T06:55:00.000-07:00

What if

I can help you earn

3X

the Compressor you buy!
------------------

Would YOU be Interested?

SupraCoolant

2009-10-16T05:50:00.000-07:00

Coolant for Rotary Twin Screw Air Compressors

SupraCoolant

Semi-synthetic Coolant for Rotary Twin Screw Air Compressors

Turbo Compressors

2009-10-15T06:55:00.000-07:00

Centrifugal Turbo Compressors:

We have 2 units of FS-Elliot Turbo compressor install in Prai Industrial Estate.
one unit = 500 horsepower.
one unit = 800 KW
New unit install and ready to start-up!
-----------------------------------
500 HP, 415V Electric Motor
-----------------------------------
A view of an 500 HP, 415 V, Electric Motor driving an FS-Elliot Turbo Compressor.

----------------------------------------
800 KW, 11,000V Electric Motor
----------------------------------------

A view of 800KW FS-Elliot Turbo Compressor:
Compressor install with an 11,000V, Electric Motor.

Another view of the Turbo Compressor

Another view at the compressor inlet side.

Top
Grey colour is the 800 KW, 11,000KV, Electric motor.
lower blue colour is the base of the compressor, also use as Oil Tank, about 2 drum of 209 litres.

Another side of the same Compressor.
On the left is 3 stage,
On the right is the 2nd stage.

Another View of the same 800 KW Turbo Compressor.

Our neighbour,
A 6500 KW, 11,000KV, Electrical motor driving a Cameron Turbo Compressor.

External Air Filter for Centrifugal 3-stage Air Compressor, install in a Factory in Perai, Penang, Malaysia.

FREE Holiday

2009-10-05T16:50:00.000-07:00

3D 2N at Local Destinations

With any purchase of Products and/or Services!
Value above RM2,000.00

Local Destinations:

Choose one!
Penang, or Kuantan, or Port Dickson, or Genting Highland,

0r
Certain Berjaya group Hotels.

International Destinations:
Choose one
5D4N stay at
Phuket, or Pattaya, Thailand

International Destination:
5D4N at
Bali, Indonesia

Terms & Conditions apply

Air End failure -AC - 03/Sept/2009

2009-09-05T17:57:00.000-07:00

A failed Rotary Screw Air Compressor's Air End:=
Atlas Copco GA132, we dismantle on Thursday, 3rd September, 2009 from a factory in Prai Industrial, Penang.

A female rotor of the twin screw rotary screw air compressor.

The male [drive rotor], note; the DE bearing side.

Air End Bearings:=

Types and size of bearings:
QJ 315 = 2 sets
NU 315 ECJ/C3 = 4 sets

Note:=
There are three types of bearing cage to choose from, there are
NU 315 ECJ = Steel cage
NU 315 ECP = Polymide cage [ a type of plastic material ]
NU 315 ECM = Brass cage

Air End failure -IR - 04/Sept/2009

2009-09-05T17:30:00.000-07:00

A failed Rotary Screw Air Compressor's Air End:=
Ingersoll Rand MM75,
[ 75kw = 100 hp ]
We dismantle on Friday, 4th September, 2009 from a factory in Prai Industrial, Penang.

A view of air end after the air end side of the gear box cover remove.

A close-up view of the same air end.

Note:
worn out part of the DE side of male rotor.
There is wear on the NU bearing inner cone bearing seat.
Meaning the inner race of the bearing is rotating on the rotor shaft.

The gear box cover that support the rotors.
Note:
The bearing support for the male rotor shaft.

Another view of the air end side gear box cover.
Note:
The male rotor side.

Air End end cover!

Another view of failed, twin screw rotor.
Note:
The male and female rotor.

The male rotor in the housing after the female rotor is been remove from the housing [compression chamber].

The male just coming out of it's housing.

The Male Rotor Before Repair !

The Male Rotor After Repair !

The rotor after repair, rebuilt, and grind to size.

Air End Bearings:
Type and sizes of bearing for this air end are:=
HM 911210 = 4 pcs
HM 911244 = 4 pcs
NU 211 ECM/C3 = 1 set
NU 311 ECM/C3 = 1 set

Note:=
There are three types of bearing cage to choose from, there are
NU 311 ECJ = Steel cage
NU 311 ECP = Polymide cage [ a type of plastic material ]
NU 311 ECM = Brass cage

A sample of a different air end using ECM bearings.
That is bearing with Brass Cage.

This Air End is for sale, for use on Ingersoll Rand M55 & M75,
55 Kw [75 hp] and/or 75kw [100 hp] air compressors.

C3 = clearance of three thou, clearance between races and roller bearings.
3 thou = 3/1000 inches.

Typical Bearings Failures

2009-08-24T06:50:00.000-07:00

Prevent over 60% of Premature Bearing Failures

Poor Fitting [16%]
About 16% of all premature bearing failures are caused by
1. Poor fitting (usually brute force ...)
2. Being unaware of the availability of the correct and proper fitting tools
3. Laziness

Individual installations may require mechanical, hydraulic or heat application methods for proper, correct and efficient dismounting or mounting.

The use of specialised tools, equipments and techniques will make the above job easier, faster and more cost effective.

These is one positive step towards long bearing life, thurs achieving maximum compressor uptime.

Poor Lubrication [36%]
About 36% of premature bearing failures are caused by incorrect specification and inadequate application of the lubrication.

Any bearings deprived of proper lubrication will long before its normal service lifespan. Bearings are usually the least accessible components of the compressors, therefore, neglected lubrication compounds the problem.

Effective lubrication, using recommended lubrication [grease, oil, coolant], Special tools, equipments, and techniques, really helps to greatly reduce downtime.

Contamination [14%]

Bearings are precision components that will not operate efficiently, unless both the bearings and its lubricants are isolated from contamination. At least 14% of all premature bearing failures are attributed to contamination.

Fatigue [34%]
Whenever compressors are overloaded, incorrectly serviced or neglected, bearings will suffer, resulting in 34% of all premature bearing failures.

Sudden or unexpected failure can be avoided, because neglected or overstressed bearings emit "early warning" signals, which can be detected and interpreted using Condition Monitoring Equipment.

Condition Monitoring Equipment
CME includes hand-held instruments, hard-wired systems and data management software for periodic or continuous monitoring of key parameters.

edited from
http://www.skf.com

A failed QJ bearing, behind is the Controller for Screw Air Compressors.

High Oil Consumption

2009-08-23T07:40:00.000-07:00

Increased Oil [Coolant] Consumption

1. Blocked drainage [scavenging] line

2. Type of Oil [Coolant]
[ oil vapour content]

3. Over filled sump

4. Air Release
[Oil foam build-up]

Rotary Compressor Coolant
One of the best for Rotary Screw & Vane Air Compressors
Mineral based, Long change intervals

Packing := 5 us gal.

Economic Service Life Of Oil Separators

2009-08-23T07:19:00.000-07:00

Economic Service Life

1. Oil Care
2. Selection of Oil / Coolant
3. Operating Conditions

1. Oil Care
Oil Change Interval!
Oil Filter Change Interval!
Air Filter Change Interval!
Oil Compatibility
Oil Contamination!

2. Selection of Oil / [Coolant]
Aging Resistance
Insensitivity with Water
Compressor Suitability
Air Separation Efficiency

3. Operating Conditions
Ambient Temperature
System Cooling Oil Temperature
Foreign Harmful Bodies in Air

Oil Separators

2009-07-02T21:11:00.000-07:00

Rotary Screw Air Compressors parts

Oil Separator Factory in Shanghai, China.

Basic Operation Principles of Oil Separation
1. Direct Interception
2. Inertial impaction
3. Diffusion

What will the effect?

Meaning, a 3 ppm rated Oil Separator Element, do not need to have a 3 micron rating, it is usually more than that, and it will get a 3 ppm performance on its' Oil Separator element.
Cool 0r Cool

Oil Separator Element Support!
Note:
The direction of Air Flow!

Oil Separator Tank with Vertically installed Oil Separator

Oil Separator Tank with Horizontally installed Oil Separator

Many newer comes with Spin-On Oil Separators, especially on smaller capacity, so far it is use on compressors up to 150 hp Rotary Screw Air Compressors.

These type are usually found installed in German Made Rotary Screw Air Compressor.
Example: Alup SCK 125, SCK 151, using 3 numbers on Spin-On Oil Separators --- [Parallel Flow]

A typical Oil Separation & Oil Lubrication combination unit.
On the left, the white colour is an Spin-On Oil separator, on the right, is an oil filter mounted on a combination unit, include MPV and Themo valve.

Commonly found on small unit, Italian made compressors,
Example:= Fiac, Fini, etc.

Trainer Profile

2009-06-20T22:29:00.000-07:00

Trainer Profile

Wong Chong Sen a.k.a. Handsome Wong

The biggest screw air compressor in the Northern Region.
Located in Penang Seagate, Bayan Lepas Industrial Estate. Penang.
The 350 kW is water cooled, and use Auto-transformer to start.

Take two day to start it up.

Industrial Robotics & Automation.

Champion Service Training

Champion Air Compressor
Sales & Service Training

City and Guild of London Institute
Electrical Engineering
Part II

City and Guild of London Institute
Electrical Engineering
Part III

City and Guild of London Institute
Electrical Engineering
Full Technological Certificate

Skilled Certificate
MLVK
General Mechanic

Member Singapore Institute of Engineering Technologists

Ultra Filters
Cleaned Compressed Air Treatment
Line filtration

----------------------------------------------------------------------
" Traditional & Brick Mortar Business "
----------------------------------------------------------------------

Certificate from Almig of Germany.
The number air compressor company in Germany.
The hot bed of air compressors manufacturing and air end productions.

Good news for those who have vast working experiences to obtain Government approved skill certificate without having to go back to school.

Note:

For adult only, with working experiences only

Air End Overhual

2009-06-20T22:04:00.000-07:00

Air End overhauls

Methodology: 10% Theory
90% practical

Accelerated learning for adults [Participating group activities]

Who should attend:
All mechanic, air compressor maintenance personnel, engineers, facilities technicians, department Heads, anyone who is interested, including self-employed businessman!

Time: 10.00 am to 5.00 pm
Duration: one-day
Date: June 26, 2009
July 3, 2009
July 10, 2009
July 17, 2009
July 24, 2009
July 31, 2009

Venue:
Workshop, 18, Jalan 5/5, Mak Mandin Industrial Estate, 13400 Butterworth.
Language: English & Bahasa Malaysia.

Course Fee

Registration & Payment
Course fee must be paid in full and is not refundable, a substitute can be nominated at no extra cost to you.
Cheque should be made payable to "Nikaya (M) Sdn. Bhd."

Note: More information, please call Wong CS at 60124982163

Note:
Nikaya (M) Sdn. Bhd. reserves the right to cancel or reschedule the program to a different date.

----------------------------------------------------------------------
" Traditional & Brick Mortar Business "
----------------------------------------------------------------------

GREAT NEWS!

Looking for Engineering & Industrial Entrepreneur [ International Partners welcome ]

Limited numbers only! For the first time!

You will learn in one year, what others normally take 5 to 10 years of hard work, really hard !

Purpose:
For Future Business Owners or Partners!
Not to get certificates or Diploma.
This is a learning, experience and to make serious money.
and
about money
Some, Mediocrity or lots of money,
depends on YOU !

Content:
Air Compressors [ Mechanical & Electrical ]
A.
Reciprocating Piston type
B.
Rotary Screw Air Compressors, including Air-End Overhaul.

Bonus 1:
Welding & Fabrications
A.
Arc Welding
B.
Gas Welding including brazing
PROJECT:
Shaft rotor support & Lifting stand.

Bonus 2:
Motor Winding

PROJECT:
Bearing heater & DOL & Star-Delta Starter

NOTE:
These are Performance based training,
--- Using adult learning methods,
--- For Future business in any of the above fields.

These courses are design for serious students and are self funding!
meaning
You will earn income while learning you trades.
Income also performance based!

Bonus 3:
Sales & Marketing

Bonus 4:
On Business Side!
Business & Life Philosophy:

We use ancient wisdom from some of the world oldest civilizations:
1.
Chinese wisdom as in I-Ching
a. Lu Chia --- present day Confucianism
b. Tao Te Ching -- present day Taoism

2.
Babylon wisdom --- present day location is Iraq

3.
Old Indian philosophy.
Especially those from my honourable Teacher, Siddhartha Gautama, a.k.a Sakyamuni, general refer to as the historical buddha.

Air Compressor Training

2009-06-20T21:52:00.000-07:00

A Course on Business Air Compressors

1. Electrical
Course content:

Star –Delta Starters for Air Compressors

What You will learn:
All major components in Star-Delta Starters; Types, Purpose & Usage.
Example: 1TR, 2TR, CB, SC, DC, MC, CR, Auxiliary contacts, NO & NC, Mechanical & Electrical interlock, MOR, etc.
Control voltage & its’ wirings, local electrical code on starters & symbols.
Major difference in starters for Air Compressors & other industrial motors.

Methodology: 90% practical {group activities]
10% theory

We use adult learning methods & Accelerated learning methods

Who should attend:
All mechanic, air compressor maintenance personnel, engineers, facilities technicians, anyone who is interested, including self-employed businessman!

Time: 10.00 am to 5.00 pm
Duration: -
Venue: Workshop.
Language: English & Bahasa Malaysia.

-----------------------------------------------------------

2. A General course on screw air compressors

Methodology: 40% Theory
60% practical

Accelerated learning for adults [Participating group activities]

What you will learn:
Types and classification of compressors,
Principles of [general] operations, Operation of twin screw air compressors,
Pressure Controls, including MPV, check valve,
Capacity Controls,
Temperature Controls, including air/oil separation
Safety Devices & Codes,
Drives Systems, Service Factors, insulation class.
Preventive maintenance,
Calculation: sizing of compressors, New and Existing {Upsize or downsize},

Who should attend:
All mechanic, air compressor maintenance personnel, engineers, facilities technicians, Department Heads, anyone who is interested, including self-employed businessman!

Time: 10.00 am to 5.00 pm
Duration:
Venue: Workshop.
Language: English & Bahasa Malaysia.

Note:
We, Nikaya (M) Sdn. Bhd. reserves the right to cancel or reschedule the program.

Course Fee:
Fee inclusive of course materials and one year coaching & Mentoring

Registration & Payment:
Course fee must be paid in full and is not refundable upon confirmation.
A substitute can be nominated at no extra cost.
Cheque should be made payable to Nikaya (M) Sdn. Bhd.
-------------------------------------------------------

NOTE:

For more information, please call
Wong CS at 60124982163

We can customize the training for your existing Air Compressors.
[Piston type, Screw type or Centrifugal Type]

----------------------------------------------------------------------
" Traditional & Brick Mortar Business "
----------------------------------------------------------------------

GREAT NEWS!

Looking for Engineering & Industrial Entrepreneur [ International Partners welcome ]

Limited numbers only! For the first time!

You will learn in one year, what others normally take 5 to 10 years of hard work, really hard !

Purpose:
For Future Business Owners or Partners!
Not to get certificates or Diploma.
This is a learning, experience and to make serious money.
and
about money
Some, Mediocrity or lots of money,
depends on YOU !

Content:
Air Compressors [ Mechanical & Electrical ]
A.
Reciprocating Piston type
B.
Rotary Screw Air Compressors, including Air-End Overhaul.

Bonus 1:
Welding & Fabrications
A.
Arc Welding
B.
Gas Welding including brazing
PROJECT:
Shaft rotor support & Lifting stand.

Bonus 2:
Motor Winding

PROJECT:
Bearing heater & DOL & Star-Delta Starter

NOTE:
These are Performance based training,
--- Using adult learning methods,
--- For Future business in any of the above fields.

These courses are design for serious students and are self funding!
meaning
You will earn income while learning you trades.
Income also performance based!

Bonus 3:
Sales & Marketing

Bonus 4:
On Business Side!
Business & Life Philosophy:

We use ancient wisdom from some of the world oldest civilizations:
1.
Chinese wisdom as in I-Ching
a. Lu Chia --- present day Confucianism
b. Tao Te Ching -- present day Taoism

2.
Babylon wisdom --- present day location is Iraq

3.
Old Indian philosophy.
Especially those from my honourable Teacher, Siddhartha Gautama, a.k.a Sakyamuni, general refer to as the historical buddha.

Heat Exchangers

2009-06-03T07:01:00.000-07:00

Hitachi Screw Air Compressor OSP37
Combined Coolers

Combined Coolers

Another view of the Coolers

Dimension of the said Coolers

Local manufactured, Aluminum alloy Air and Oil Heat Exchanger materials for Rotary Screw Air Compressors.

Motor Failure

2009-02-02T22:09:00.000-08:00

Motor Failure
One Coil or phase short circuit to earth! We can wired to last longer, more than one year of normal use!
View 1
View 2
View 3
Repair to motor shaft sleeve using speedi-sleeve
View 1
View 2
View 3

Oil Vapour in Compressed Air

2009-01-17T05:06:00.000-08:00

The quantity of oil vapour in compressed air depends on:

* Type of oil [coolant]
* End temperature after compression
* Outlet temperature of the compressed air
* Working pressure

NOTE:
Oil Vapour passes all air/oil separator elements
That is, at temperature of 100 degree Celsius, up to 5 times more oil goes through than at temperature of 80 degree Celsius.

If you have a perfectly balanced air/oil separator, then the high oil consumption, due to high oil carry-over to compressed air could be:

* Oil return (scavenging) pipe is blocked
* Oil return (scavenging) pipe too short, not of the correct length
* Oil specification wrong
* Oil vapour too high [due to high temperature]
* Oil level too high
* Air refine efficiency is bad
* Too much oil foam

Characteristic of Compressed Air

2009-01-17T01:33:00.000-08:00

Characteristic of Compressed Air

* Compressed air is bearer of heat energy
* Compressed air can bridge certain distance
* Can be stored
* Flashed air delivers power
* Air delivers large volumes of water

Sample Service Contract

2009-01-16T18:32:00.000-08:00

Sample Service Contract
[for your reference only, we recommend you use you own version]
1. Cover Letter
2. Service Contract
3. Schedule
4. Scope of Work

-------------------------------------------------------------------
1.
Cover Letter

Our Reference:
Date:

Dear Sirs/Madam: [customer's person name]
Proposal/Renewal of Service Contract

We take great pleasure in presenting to you the service agreement proposal. Our plan is unique in the compressed air business; design to keep your compressed air equipments operating at optimum and maximum efficiency, 365 days a year, at the lowest possible running cost.

It is a well-proven and widely recognized that, preventive maintenance that provides regular, professional service and repair, over a period of time will save you operation cost, thus providing maximum operational efficiency.

It give your compressor optimum performance, maximum productivity and financial security. With fixed maintenance [parts & labour], you will avoid hidden surprises and unnecessary breakdown of your compressor, it provide you total peace of mind to focus other more urgent task.

Our technicians are regularly trained, updated with the latest service development, and equipped with the latest tools.

We are confident that you will consider our proposal favourably.

On your approval, kindly endorse the two copies of this agreement and returned to our office with advance payment. The original copy will be returned to you after processing.

Validity of this proposal is 30 days from the date of this letter.

Assuring you of our best service.

Yours Sincerely,

--------------------------------
[Name & position]

..............................................................................................
2.
Service Contract

Our company offers service arrangement under contractual basis. This arrangement is highly recommended, not only planned service could be arranged, it also ensures the required maintenance is carried out, minimizing unforeseen breakdown.

This contractual arrangement, covers two different activities, they are:

A.
Inspection Contract;
Visit at pre-determine interval to conduct inspection and recommend any necessary service or repair necessary!

B.
Maintenance Contract;
Visit at pre-determine interval to carry out prescribed work, including periodic service.

1.
AGREEMENT

Between
[Customer name & details]

Hereafter referred to as the Customer.

2.
This Agreement cover the following equipment:

Brand:
Model:
Serial Number:
Horsepower:
Number of Units:
Installed at:
Contact Person:
Tel:
Fax:

Remarks:

3.
Validity
This agreement is valid for [..............] year(s), starting from the date [............].
This agreement can be terminated by either party in writing with one-month advance notice.

4.
Extent of this Agreement
4.1
Preventive maintenance will be carried out [...........] times a year.
4.2
The equipment covered by this agreement shall not exceed [.............] hours a year.
4.3
The inspection and maintenance of the equipment will be according to manufacturer's recommendation.
4.4
Agreement price includes labour and specific parts required for each maintenance visit, unless otherwise stated in cluase 2.

5.
The Agree price will be RM[..............] per year.
Invoice will be carried out once a year prior to the first maintenance visit. Payment must be received prior to the first maintenance visit.
{Note: Price is locked in for the year, guarantee no price increase for the year}

6.
The Responsibility and Rights of both parties.

6.1
The customer will perform the daily and weekly maintenance in accordance with compressor's instruction book. The customer here-by confirms that he has a copy of the instruction book, and ensures the compressor logbook is filled in daily.
6.2
[Company name] may contact the customer before the planned time and date for each visit. The customer will then ensure the compressor equipment is available for maintenance.
6.3.
Maintenance will be carried out during normal working hours, unless specified in clause 2. Any extra cost as a result of deviation in original schedule will be invoiced to the customer accordingly and separately.
6.4
If any major changes occur in the operation or site conditions of the compressor equipment, this agreement will become null and void. This includes factors such as ventilation, power and water supply.
6.5
[Company name ] will submit a service report on the condition of the compressor equipment to the customer after each preventive maintenance visit.
6.6
[Company name] will not accept any liability whatsoever for any bodily injury to any person, damage to property or other consequential loss, unless it can be proven that [company name] has been guilty of gross negligence.
6.7
The customer will give all necessary assistance by providing necessary lifting equipment, lighting etc.
6.8
In the event of any supplemental work arising as a result of the maintenance inspection that is not included in this agreement, [company name], however can and will carryout this work and invoice the customer separately based on customer approval and acceptance.

7
Limitation of Responsibility

7.1
[Company name] reserves the right to refuse or stop any further service if any outstanding bills are not paid.
7.2
[Company name] will not be responsible for any compressor equipment malfunction or damage if routine maintenance according o clause 6.1 is neglected or customer's failure to comply with repairs recommended by [company name].

8.
[Company name] standard warranty of 3 months or 2000 hours applies to all repair work, including part, whichever come first.

Signed for and on behalf: [customer]

Signature:
Company chop:
Name:
Position:
Date:

Signed for and on behalf: [company name]

Signature:
Name:
Position:
Date:

.............................................................................................

3.
Schedule

Average Running Hours per Year

2,000 hours +++++ 4,000 hours +++++ 6,000 hours +++++ 8,000 hours
-----------------------------------------------------------------------------------------
Y
E
A
R

1
-----------------------------------------------------------------------------------------
Y
E
A
R

2
-----------------------------------------------------------------------------------------
Y
E
A
R

3
--------------------------------------------------------------------------------------
Y
E
A
R

4
-------------------------------------------------------------------------------------
Y
E
A
R

5
------------------------------------------------------------------------------------

4.
Scope of Work

Period:
1,000/2,000 hours, Monthly visit
Scope of Work:
Measurement of temperature, condition monitoring, air jet clean coolers, motor and compressor.

-----------------------------------------------------
Period:
1,000/2,000 hours, Every 3 months
Scope of Work:
Replace oil filter, clean air filter [replace if necessary], replace compressors coolant, external air jet clean compressors, motor and coolers.

----------------------------------------------------
Period:
4,000 hours or 1 year (12 months)
Scope of Work:
Replace all items from above and, replace air/oil separator element, service moisture trap, grease main motor. Change belts if belt driven units.

-----------------------------------------------------
Period:
8,000 hours or 2 years
Scope of Work:
All of the above, plus, service oil stop valve, inlet valve, Vent valve, MPV, Replace belts.

----------------------------------------------------
Note:
Scope of works may vary for different compressors and model, based on factory's recommendation.

.............................................................................
Extended Warranty Options:
* Air end Cover: Y/N
* 5 years warranty: Y/N

Value Added Options:
* After working hours service: Y/N
* Off-day Service: Y/N

Accessories:
* Dryer service: Y/N
* Main Line Filter Service: Y/N
* Air Receiver auto-drain service: Y/N
* Others (please specified): Y/N
..........................................................

Pre-Owned Screw Compressor -- > 50 hp

2009-01-15T00:19:00.001-08:00

Used, Good Quality Screw Type Air Compressors

RotorComp, NP2075

---------------------------------------
One unit of Ingersoll Rand, ML55 air-cooled for sale. [75 horsepower]
92 M55 E78132
Unit Price: RM28,000.00, Ex-Butterworth.
Outside view
Another view of the inside
Another view of the inside!
---------------------------------------------------------------------------------------------------
One unit of RotorComp, Germany
Model: NP2075
Year:
Price:
Ex-Work, Butterworth, Penang,

Another Inside View

Another Front View
Using Vertical Oil Separator tankView of Inlet Control Valve

-----------------------------
One Unit, Ingersoll Rand ML 45, year 1992
Unit Price: RM21,000.00, Ex-Butterworth

-----------------------------------

One unit oversize, Ingersoll Rand ML22 Rotary Screw Air Compressor Body & Housing.
Modify and install with an Ingersoll Rand 20hp Air Compressor Motor.
Frame, oil separator tank and cooler is from ML22, 30 hap screw compressor
Selling price = RM12,000.00
Warranty = 12 months.

Pre-Owned Screw Compressor -- < 50 hp

2009-01-15T00:18:00.000-08:00

Used Screw Type Air Compressors
[with and without warranty]

one unit
Kobelco Variable Speed Drive
50 hp Air Compressor
year 2003, like NEW!

Another view of the same Compressor

------------------------------------------------------------------
2 units
Ingersoll Rand ML37 air-cooled, Year 1995, Unit Price = RM20,000.00, Ex-Butterworth
Ex-Butterworth, Penang, Malaysia
View 1, Front panel
Another view, Cooling fan Oil separator tank with JKKP certificate
-------------------------------------------------------------------------------------------
CompAir Cyclone C337
50 hp Twin Screw type, Belt drive Air Compressor.

-------------------------------------------------------------------------------------------
Ingersoll Rand MH22, 30 Horsepower
91 M22 E37385, Year 1991, Unit Price = RM17,000.00 Ex-Butterworth
come with JKKP certificate
----------------------------------
Another unit, with ML22, 30 hp Ingersoll Rand Rotary Screw Air Compressors's frame and size. Modify and install with an Ingersoll Rand 20hp Air Compressor Motor, especially good for high dust industries example wood working factories.
Selling for RM12,000.00
warranty = 12 months

--------------------------------------------
Ingersoll Rand
One Unit MH15, Year 1998, Unit Price: RM13,500.00 Ex-Butterworth

-----------------------------------------------------------
One unit
used SMC Compressed Air Dryer
Model: IDF37C

Another view of the same Air Dryer

Pre-Owned Piston Compressor - less than 10 hp

2009-01-15T00:17:00.002-08:00

253H7.5

Used Piston Type Air Compressors
[with and without warranty]
Ingersoll Rand, 253H7.5
Year 1988, Unit Price: RM4,800.00 Ex-Butterworth
253H7.5, View 1
253H7.5, View 2253H7.5, View 3

Pre-Owned Piston Compressor - 15 hp

2009-01-15T00:17:00.001-08:00

Used Piston Type Air Compressors
[with & without warranty]

Ingersoll Rand Piston Type, two-stage air compressors.7100E15M, 15 Horsepower, year 1998, Unit Price: RM6,500.00 Ex-Butterworth7100E15M, 15 Horsepower, year 1990, Unit Price: RM6,500.00 Ex-Butterworth7100E15M, 15 Horsepower, year 1996, Unit Price: RM6,500.00 Ex-Butterworth
Note: on the left is Ingersoll Rand 7100E15M, Right side is Swan SWU-415
3000E20M, 20 Horsepower, Year 1996, Unit Price: RM7,000.00 Ex-butterworth
Model: 3000E20M, View 1
3000E20M, View 23000E20M, View 3
-----------------------------------------------------------------------------------
Swan Piston, single stage

SWU-415, 15 Horsepower, Year 1996, Unit Price: RM5,000.00 Ex-Butterworth

Pre-Owned Piston Compressor - 10 hp

2009-01-15T00:16:00.000-08:00

Used Piston Type Air Compressors
[with & without warranty]

Quantity: One Unit
Brand: Ingersoll Rand
Model: 253, [5" & 3" X31/2"]
Year: 9621872
Motor HP= 10 horsepower

Unit Price: RM4,800.00 ex-Butterworth
Another view of the same compressor

One view, the compressors at my workshop.
Another top view to the same compressor

Brake Horse Power

2009-01-12T22:00:00.000-08:00

Power and Efficiency

Brake horsepower is the input power required at the compressor input shaft for a specific speed, capacity, and pressure condition.
Motor horsepower is the nominal rating of the prime mover.

The service factor is the additional power built into an electric motor above its nominal rating - expressed as percent. Within the service factor, the brake horsepower driving an air compressor can be higher than the motor's nominal horsepower.

The power efficiency of a compressor is the ratio of the air delivered by the compressor and its input electrical requirements.

Efficiency usually is expressed as brake horsepower per 100 cfm of delivered air.

Small Reciprocating Compressor

2009-01-12T21:55:00.000-08:00

Small Reciprocating Compressors

You do not have to hire an outside service company to work on your small reciprocating compressors. We are pleased to offer a unique book, to help you repair these compressors.

The book is easy to understand with useful information, such as the following:

• Explanations for the various components, including illustrations with exploded views.
• Simple diagrams that describe how the controls work.
• Maintenance tips on the 4 most common reasons small reciprocating compressors fail.
• An in-depth trouble shooting guide that includes specific actions to solve each problem.

Order today. The book will pay for itself – many times over the years – by eliminating the need for outside vendors to help with repairs.

Table of Contents

This book has a soft cover with 25 pages filled with material on every aspect of the small reciprocating compressor. Here is a list of the topics.

Chapter 1, Introduction
a) Compressed Air Terms
b) Definitions

Chapter 2, Types of Air Compressors
a) Reciprocating, single and multi stage
b) Rotary Vane
c) Rotary Screw
d) Diaphragm

Chapter 3, Nomenclature
a) Pumps
b) Receiver Tanks
c) Motors
d) Safety Devices
e) Accessories
This includes details on the check valve, centrifugal unloader and aftercooler.

Chapter 4, Controls
a) Starting Controls
b) Operating Controls

Chapter 5, Installation
a) Location
b) Pipe Size
c) Wire Size

Chapter 6, Trouble Shooting
a) Common Failures
b) Diagnosis
c) Correction Procedures

Chapter 7, Overhaul Procedures
a) Minor Overhaul
b) Major Overhaul

Chapter 8, Maintenance
a) Recommended Schedule
b) Reference Charts

Air System Design

2009-01-12T21:50:00.000-08:00

Compressed Air System Design

The most economical way to have an efficient compressed air system is to start at the beginning. We can help you design a new compressed air system from scratch, redesign an older system to increase efficiency, or redesign expansion systems to fit into existing systems.

All manufacturing plants can benefit from having a specialist in compressed air involved during the design phase. Often times, engineers who execute plant designs may be great when it comes to general engineering, but are lacking experience in compressed air systems. Most design firms don't generally have compressed air specialists on staff because it is a small part of their overall business.

However, some very small mistakes related to compressed air system design could result in major losses of time, productivity and efficiency.

We are the professionals; measure and troubleshoot compressed air systems every day. We know what works and what does not work. Many of the systems we encounter in the field have problems due to incorrect piping, false pressure signals to the controllers, high-pressure loss, high velocity and turbulence to the system.

Any of these problems can lead to thousands of dollars in lost energy. Because we are not aligned with any equipment manufacturer and take no part in the sale of any compressed air equipment, we can assist our customers in evaluating and making honest recommendations for the components that are right for your operation.

For more information on compressed air system design services, contact us.

Belt Drive Failure

2009-01-12T21:47:00.000-08:00

DO YOU KNOW?

Improper belt maintenance is the leading cause of belt drive failure.
Next in line are improper installation, and environmental factors.

typical belt tensioner as found installed in small size, Italian made Screw Air Compressors.

Air Receivers

2009-01-12T21:09:00.000-08:00

Air Receivers

Every compressed air system needs a receiver, but the receiver alone is not always the answer to energy efficiency in the system.With its dumpy fat cylindrical shape, dull-painted exterior, lack of visible dynamic activity, and frequently hidden location, it's easy to understand why the air receiver usually is the orphan of the plant-air system family. There is confusion and controversy over its function, where it should be located, what size it should be, how it should be piped - and whether an air receiver is needed at all.

Air receivers are one of the least understood, yet potentially most useful components available to increase operating efficiency.

But an air receiver should be an integral part of any plant air system - mainly to enhance its efficiency.

Here are the classic purposes:

Contaminant removal - A bare receiver (without a pressure regulator or flow controller) adds a large volume to the piping system. This volume reduces air-flow velocity and encourages finely divided particles of liquid lubricant or condensate to drop out of the air stream. These separated liquids then can be drained from the receiver, rather than traveling with the compressed air to produce adverse downstream effects.

Pulsation dampening - A receiver installed near the compressor discharge dampens pressure pulses from positive-displacement compressors (rotary or reciprocating) to a small fraction of their original amplitude. This reduces the probability of excess compressor power or shortened service life resulting from rapid recycling of the compressor.

Pressure stabilization - A receiver combined with a pressure regulator or flow controller can create an effective pressure band or differential between the supply side and the demand side. A typical example: 95 psig in the receiver, 90 psig steady to the system. This will allow the demand side to operate at its lowest effective pressure, and therefore lowest volume demand. Stored air with a pressure differential creates volume held in reserve to cover short-term peak demands that exceed current air supply.

Controlling energy costs
When industry management began to focus on energy-cost control as a weapon for reducing production costs, energy managers soon realized that compressed air was their most expensive utility. After all, it takes 8 hp of electricity to produce 1 hp of compressed air. Air no longer was perceived as free. Its cost should, and could, be managed.

Early efforts in compressed-air cost management focused on the obvious - control of leaks and lowering usage.

Without effective storage, most unloading controls could not establish and hold enough idle time as a percent of running time. Nor could they optimize the automatic start/stop control and shut off.

Compressed Air

2009-01-12T21:02:00.000-08:00

Compressed Air

The atmospheric pressure of air, which are measured barometrically, vary depending upon its position relative to sea level.

When air is compressed above atmospheric pressure, its characteristic is to attempt to return to its normal state. Since compression of air requires energy input, energy is then released as compressed air returns to atmospheric pressure.

Compressed air is one of the most versatile and useful forms of energy available. It is used to operate automobile lifts, inflate tires, operate tools, spray paint, many automated machinery in production plants and many other uses in all industries.

Compressed Air for Power
Compressed air is widely used for power. Internal energy stored in compressed air is directly convertible to work; no conversation from another form of energy such as heat is involved, at least not at the point of used. Pneumatic components are therefore characterized by a notably high ratio of power to weight or power to volume. Compared to equipment, which involve translational forces in a variable force field, compressed air produces smooth translation with more uniform force. Not as fast as electricity, nor as slow as hydraulic, pneumatics finds a broad field of application for which its response and speed makes it ideally suited. Where there is an overlap, the choice is often one of economics, and air is likely to hold the advantage. In addition, air doers not possess the potential shock hazard of electricity nor the potential fire hazard of oils.

The attributes of compressed air lead to its application in many different kinds of components. Pneumatic tools producing torque and rotation such as drills, brushes, nut runners and screw drives are common examples. These are generally powered by some form of rotary air motor such as the vane or lobe type, or by an air turbine. Equally common are components producing lateral motion and direct force, either steady or intermittent, with either manual or automatic control. Common examples are clamps, presses and automatic feeds. Often air pressure is used to accelerate a mass, which then exerts an impact upon an anvil, as in paving breakers and pile drivers. Common applications in industrial plants and or construction sites are air powered nailers and staplers.

In paint spraying and, to a considerate extent, in air conveying, motion is impacted essentially by the dynamic pressure of the air.

Advantages of Air Power
High ratio of power to weight in air tools contributes to low operator fatigue.
Air tools run cooler; do not generate heat in performing work.
Air tools have variable speed and toque control.
Compressed air is clean, has no fire hazard, no electric shock potential.

Pneumatic vs. Electric

Safety … Air powered equipment reduces the danger of electric shock and of fire hazard. Air tools run cooler and have the advantage of not being damaged from overload or stalling.

Lightweight … The air tool is lighter in weight and lends itself higher rate of production per man hour with less worker fatigue.

Flexibility … Due to its ability to provide a source of power by means of engine driven portable compressors, air tools can be operated in areas where other power sources are unavailable.

Cost … Due to fewer moving parts and their simplicity of design, air tools provide low cost maintenance and operation.

Pneumatic vs. Hydraulic

Safety … Unless fire resistant fluids are used, hydraulic-powered components operating near open flame or high temperatures present fire hazards. Compressed air components operate with lower system pressures. Accidental air leaks release no contaminants, as with hydraulic.

Low Initial Cost … Fewer parts make up a pneumatic system and the use of a single compressed air supply permits operation of many separate systems. Simple and less costly controls are possible with compressed air.

Flexibility … Compressed air systems provide for simpler installation, particularly where tools are frequently interchanged, such as in automotive service. Compressed air systems offer good adaptability for automation and flexibility for changing or expanding operations.

Maintenance … Pneumatics have less down time than do hydraulics, which have more complex controls and systems. Less preventive maintenance is required with air, whereas hydraulic fluids must be monitored and replaced periodically.

Leakage … Leakage in hydraulic systems results in the presence of hydraulic fluids that are dangerous to the surrounding area, whereas pneumatic system leaks do not contaminate the work area. In addition, leaks in hydraulic systems can result in complete system shutdown.

Summary
Benefits of Compressed Air:
* Easy to transport
* Easy to store
* Clean and dry
* Low weight
* Safe operation
* No accident hazard
* Rational and economical
* Simple
* Safe against overload
* Fast working medium
* Continuously graduable

Look Beyond the Sticker Price

2009-01-08T21:17:00.000-08:00

Look beyond the sticker price when buying an air compressor

It’s the total cost of ownership that should guide you.

When shopping for air compressors, it pays to look beyond the sticker price before you make your decision. The startling fact is that the initial price represents a mere 15% of compressor costs over a 5 to 7 year period.

Smart & savvy purchasing professionals know how to look under the hood, so to speak, when they make their choice.

ENERGY Cost
Buying an energy efficient compressor saves you tens of thousands of dollars in the long run. Compressors are not by their nature very energy efficient. In fact, it can take 7 to 8 hp. of electric power to produce 1 hp. of compressed air power. Energy costs for operating a compressor can exceed the initial cost of the compressor in the first year alone.

Efficient Operations
One way to run a compressor efficiently can be to operate the compressor in a load-no load mode. When in this mode the compressor is either running full loaded, or, when system demand is satisfied, running completely unloaded and blown down.

Of course, it's not wise having a compressor that is always unloaded. To avoid paying a premium for something that sits idle, ensure that your compressor is sized properly to match your needs--both present and in the near future.

Although load-no load is touted as a high efficiency feature, there is a catch. Unless there is a sufficient amount of air receiver capacity--including the volume of air in the piping system--this feature can be energy inefficient.

There needs to be a minimum of 10 gallons of receiver capacity for every cubic foot per minute the compressor delivers. The larger the capacity of stored air, the longer the compressor can remain blown down and operating at a reduced horsepower.

Whenever a compressor's system blows down, compressed air vents to atmosphere. In effect, you're throwing money away by discharging air, you paid money to compressed.

Partial Load
With partial loads the compressor produces compressed air at less than full capacity. The trick is to reduce compressor capacity while maintaining the minimum pressure required. Various methods are used.

Inlet valve modulation, works by controlling the position of the inlet valve that opens and closes in response to system demand. Although extremely responsive, it is the least efficient way to run a compressor partially loaded.

Another way to part load a compressor is by controlling the rotor length. A turn-valve or poppet-style valve unit opens windows up as demand decreases. The inlet valve remains fully open so the compression ratio is not affected.

Instead, the length of the rotor is shortened. At 70% capacity, a turn valve unit can achieve 78 percent brake horsepower--a 13 to 15% energy savings over inlet valve modulation.

Other ways to control the capacity on positive displacement compressors is to control the speed--rpm--through a variable frequency drive on the electric motor.

When buying an air cooled compressor, don't forget to figure in the cost of the fan motor when calculating energy costs. A 100 hp. compressor may use a 3 hp. fan. Likewise, a 500 hp. compressor uses a fan requiring 15 to 20 hp.

High efficiency motors have a higher initial cost, but, over the long run, save money. A standard motor has a 91 to 92% efficiency rating. A high efficiency motor can operate at as high as 96% efficiency.

However, the efficiency rating vary with horsepower.

For example, 50 hp. high efficiency motors have ratings from 92.4 to 93% efficiency and 200 hp. motors have efficiency ratings from 94.5 to 95% efficiency.

Coolers
The size of a compressor's cooler also plays a role in reducing costs. Controlling oil temperature in an oil-flooded rotary screw compressor is a real balancing act. If the oil temperature is too high, it preheats the incoming air. Operating a compressor with a discharge temperature of 190° F versus 175° F can cost 1-1/2 to 2% in overall efficiency, not to mention what happens to the oil.

Keeping the oil cooled and clean pays big dividends. Many people don't think of cleaning their cooler, but by cleaning it with detergent and water, and blowing it out well, the discharge temperature could drop 20° F. That doubles the life of your oil, not to mention the day-to-day efficiency of operation.

High oil temperatures mean lower oil viscosity. This results in reduced lubrication for your bearings. The life of your bearings determines the life of your compressor.

On the other hand, oil that is too cool allows condensate to form in the system. It is important & necessary to keep any water in a vapour state until it can be removed in the aftercooler--harmlessly.

Discharge oil temperatures much below 170° F may cause condensate to drop off in the oil. This increases the oil level in the system. It also causes the increase oil carryover. A thinner oil does not provide effective lubrication and internal parts can be damaged.

Bearings
The size and quality of the bearing can have an effect on the life of a compressor. Most manufacturers choose a bearing with a L10 life of 100,000 hours.

L10 life--once known as B10 life--is the theoretical fatigue life of a bearing in which 10 percent of the population of bearings will fail under ideal conditions.

Unfortunately, very few compressors operate under ideal conditions because of inconsistent or inadequate maintenance.

Experience has shown that a compressor with an L10 life of 100,000 hours needs to be overhauled every 30,000 to 32,000 hours--4 years of round the clock service.

The size of the bearing is determined by the size of the rotor. The larger the rotor, the larger the bearing. Also, as rotor size increases, rotor speed decreases.

A compressor running at a lower speed--1,500 rpm--tends to be more forgiving than one running at a high speed--3,000 rpm or more.

Contamination
In the course of daily operation, it is common to have dirt or other contaminants enter the compressor. Dirt and debris cause more damage to a compressor with small bearings running at a higher speed, than to one with larger size bearings operating at a lower speed.

Also there is a direct relationship between noise and higher speed compressors.
Low speed[rpm]=Low Noise; High speed[rpm]=Loud Noise.
Noisy compressors require either sound enclosures, a separate room, or both.

Installations
Installation costs may need to consider when purchasing your compressor. Although rotary screw compressors need only a level floor beneath them, expenses can mount when connecting a compressor to your plant air system.

Look for compressors that have piping and wiring connections near the edge of the frame. These are much easier and less expensive to install.

It is also wise to consider the labour costs involved in working on compressors. Beware of compressors whose consumable parts are not easily accessible. Look for maintenance reducing design features like simplified access to an air-oil separator and filters, as well as spin-on filters. These design features can cut maintenance time by up to 90%.

It's best to have all electrical lines in conduit--tucked out of the way--where they won't be damaged by liquids, oil spills, or chemicals found around compressors. These contaminants break down the wiring insulation, creating a safety hazard.

Price of consumable parts
Compressors with the lowest price tag may carry aftermarket - consumable parts with the highest price tags. When comparing compressors, look closely at the cost of aftermarket - consumable parts.

Maintenance
When it comes to maintaining a compressor, make sure that you have a consistent maintenance program. Including regular briefing & training of your technicians.

If you do not have the personnel to perform the maintenance, obtain maintenance agreements through a distributor that sells the compressor.

Nothing has a greater impact on the life of a compressor than a quality maintenance program.

Finally, in conclusion
When comparing compressors, be careful to compare apples to apples.

Look beyond the sticker price to the rated efficiencies, oil carryover levels, cost of aftermarket - consumable parts, ease of installation, ease of maintenance, easy availability of aftermarket parts and service support.

The initial price is important, but the real value is what you get for that price in terms of energy efficiency, reliability, and maintenance costs.

Air Dryer

2009-01-08T21:05:00.000-08:00

Compressed Air Dryer

Two common types of dryers are refrigeration and adsorption (desiccant). When choosing a dryer, a general rule is to first select a pressure dew point that meets the requirements of the application and is 15° to 20° below the plant's lowest ambient conditions.

(A dryer's efficiency is measured as the dew point, which is the level of dryness in a compressed air system.)

Dew point determines the major difference for selecting either refrigeration dryers or desiccant models.

Refrigeration dryers cool air to a pressure dew point of 2 to 10°C, which is the effective limit on this type of dryer, as water freezes at 0° C. This style is ideal for general industrial applications in light assembly, including those that use air motors, air tools, valves, cylinders and rotary actuators, and painting and welding equipment.

When piping is installed in ambient temperatures below the dryer dew point (i.e., systems with outside piping), refrigeration dryers are not suitable.

Adsorption dryers pass air over a regenerative adsorbent material that strips moisture from the air. These types of dryers are extremely efficient and can provide a pressure dew point at 7 barg as low as -40° C. Desiccant dryers remove liquid from the compressed air system through the use of chemical beds.

A portion of the dried air is usually drawn off, passed through the chamber being regenerated, and discharged to atmosphere.

Clean Air System

2009-01-08T20:32:00.000-08:00

How to select Air Dryer

The right air dryer for the application
Selecting the right dryer requires a combination of evaluating technical factors with actual field experience.

Factors include the type of system, size of connecting lines, water capacity, flow capacity (system size), filtration capability, construction materials (i.e., steel or copper), and safe working pressures.

For Refrigerated Compressed Air Dryer:

Step 1:
From catalogue or brochure furnish by supplier;
From Charts; Conditions (Inlet temperature & Air Pressure)
Inlet Air Temperature Co-efficient, let it be = A
Air pressure C0-efficient, let it be = B

Step 2:
To Calculate the necessary air handling capacity for the model to be select;
Therefore; Air Capacity (Air dryer) required = inlet air volume (Flow rate) / [A x B]

Step 3:
Then select the suitable air dryer for the specification above the calculated air dryer capacity.
We therefore choose the Air Dryer model with handling capacity more than the calculated figure.

Benefits from using Air Dryers
Low-pressure dew points derived from implementing air dryers helps prevent corrosion and inhibits the growth of micro-organisms within the compressed air system. Corrosion causes rust and pipe scale that, over time, breaks away and causes damage or blockage in production equipment and, in some cases, can contaminate final product and processes.

Moist air provides an ideal environment for the growth of micro-organisms. If only a few of these bacteria or viruses enter a sterile process or clean production system, damage may result, diminishing product quality or rendering a product unfit for use.

Air dryers are not the same!

Products for the filtering and drying compressed air are often selected because of their initial lower purchase cost, with little regard for the air quality they provide or the cost of operation and maintenance throughout their life cycle.

Dryer equipment with a low purchase price may turn out to be a costly investment in the long run. While initial purchase costs are important, air quality, energy efficiency, and lifetime costs are the real issues.

Poor air quality with too much moisture can damage components in the air system, as well as to end products – costing a manufacturer in terms of both money and reputation. Quality air dryers also minimize pressure loss, a major contributor to operational costs, thus reducing energy consumption.

And finally, quality air dryers last longer than lower priced models, reducing downtime and maintenance costs while contributing to increased output.

By improving air quality, lowering energy consumption, and minimizing maintenance, air dryers from leading providers can reduce the total cost of ownership and improve a manufacturer's bottom line through improved production efficiencies.

Shaft Seals

2009-01-02T18:22:00.001-08:00

Shaft Seal
Basically, There are 2 types of seals in use on Air Compressors air end:
Lip seal & Mechanical seal.

Typical lip seal

Air End Bearing

2009-01-02T18:20:00.000-08:00

Some Air End Bearings from our store
QJ Bearings
NU Bearings
Roller bearings

Motor Bearings

2009-01-02T18:09:00.000-08:00

Maximize Bearing Life Cycle
Mounting and Lubrication

Mounting is one of the critical stages of bearing's life-cycle. If the bearing is installed properly using the correct method and tools, the bearings service life-time will be greatly reduced.

Lubrication is also an important step in the installation procedure. Selecting bearing grease suitable for the compressor application is critical to achieving optimum performance.

Further more, the quantity of correct grease and the lubrication method used can positively influence the service life of the bearings.

Re-Lubrication
When put into operation, the bearings require correct re-lubrication practices to optimise its performance.

Selecting the correct bearing grease and applying the right quantities at correct intervals are essential for achieving the maximum service life of the bearing.
Additionally, the re-lubrication method used can positively contribute to optimising the bearing's service life. Continuous lubrication using automatic lubricators, single or multiple-point, provides more consistent, correct and contamination-free supply than manual re-lubrication methods.
Alignment
After the bearing has been installed in an motor or pump, the set should be aligned. If it is not properly aligned, the misalignment may cause the bearing to suffer additional load, friction and vibration.

These can accelerate fatigue and reduce the bearing, as well as other machine components service life. Increased vibration and friction can greatly increase energy consumption and the risk of premature failures.

Basic Condition Monitoring
During operation, it is important to regularly inspect the condition of the bearing by performing basic condition monitoring, such as temperature, vibration and noise measurements.
These regular inspections will allow the detection of potential problems and help to prevent unexpected compressor break-down.

Consequently the compressor maintenance can be planned to suit the production schedule, thurs, increasing the plant's productivity and efficiency.

Dismounting
At some point in time, the bearing will reach the end of its service life and will have to be replaced. Although the bearing may not be used again, it is extremely important to dismount [dismantle] it correctly so that the service life of the replacement [NEW] bearing is not compromised.

Firstly, the use of proper dismounting methods and tools will help prevent damage to other machine components, such as shaft and housing, which are often re-used.

Secondly, incorrect dismounting techniques can be hazardous to the operator.

Dismounting Tools
Sample of Some of the dismounting hand tools in used!
1. Two-leg version
2. Three-leg version

Source from http://skf.com

Water in Air

2009-01-02T18:05:00.000-08:00

Cleaned Dried Compressed Air
Proper selection and application of air dryers maintains system reliability and longevity.

Most maintenance and production engineers would say that oil is the major contaminant in their compressed air system.

Wrong!
Nearly all of the total liquid contamination found in a compressed air system is water, with oil being a small part of the overall contamination problem. Filter systems can remove oil and dust, but dryers are required to remove water and adjust humidity.

How much water is actually in your compressed air system?
The answer might surprise you.
A small 100 cfm compressor and refrigeration dryer combination, operating for 4000 hours in typical northern Malaysia climate conditions, can produce approximately 2200 gal of liquid condensate per year!

Failing to remove this moisture from a compressed air system can result in condensation in piping, pneumatic tools, and instruments, leading to damage and premature failure.

Water, water, everywhere
Simply put, atmospheric air contains water vapour.
The air's ability to hold water vapour is dependent upon its temperature.
As temperature increases, the level of water vapour held by the air increases.

During compression, air temperature is increased significantly, which allows the air to retain more incoming moisture. It takes 7.8 ft3 of free air to generate 1 ft3 of compressed air at 100 psig.

After the compression stage, air is typically cooled to a usable temperature, reducing the air's ability to retain water vapour. A proportion of the water vapour condenses into liquid water and is removed by a drain fitted to the compressor after-cooler.

Further condensation occurs as air is cooled by the air receiver, piping, and as it expands in valves, cylinders, tools, and machinery.

When air is compressed, the dirt & foreign particles are not remove but they become concentrated to the maximum through the process of compression.

Condensed water and water aerosols can cause corrosion to the storage and distribution system, as well as damage to production machinery and an application's end products.

Liquid water can also wash away pre-lubricants on the cylinders and valves, decreasing their operational life.

Water in a compressed air system also reduces production efficiency and increases maintenance costs.

More Air End Failure Photos

2009-01-02T17:49:00.000-08:00

More Air End Failure Photos
Atlas Copco GA75, male drive rotor Shaft failure at gear location!

Worn out side of Motor drive gear, due to poor installation.
Loose wear sleeve rubbing against the gear face! on motor side
Repair by US, Air end cover broken by inexperience repairman or technicians, note the top side of cover, we need to join by welding and surface grind the Cover end face.
Air end failure- Drive rotor [MALE] stuck to front end cover.
Another view of the Fail Air End. Note the male drive rotor face.
A sample of EcoAir D100 air end.
Fail Air End, EcoAir D25, foreign particles into the close clearance within the screw elements.

A sample of Ingersoll Rand, ML22 gear drive design, air end size [diameter] of 100 mm.

A failed Air End Bearing,
Type QJ

Motor Shaft Repair

2009-01-02T17:43:00.001-08:00

Most common failure of Main Electric Motor Drive:

[Sample photos of Ingersoll Rand ML22, integral gear drive design due to poor or no maintenance, eg. apply of motor grease]

Worn out bearing seat, usually on Drive End [DE]
After & Before Rotor shaft repair

Recession - Crisis

2008-12-31T23:15:00.000-08:00

What Recession ?

Action L.I.F.E. Coach

Air Compressor Sizing

2008-12-28T01:45:00.000-08:00

Air Compressor Sizing

3 Simple Ways on How to Select an Air Compressor

Two basic scenarios present to decide!
1. New Plant, and 2. Old Plant [to upgrade or downgrade]

1. New Plant
Step 1, Group all equipment in loading or usage categories.
If equipment is in use most or all the time into one group = 1. (100% loading)
Example: Production machinery, SMT, Conveyor etc

Another group or groups may be .6 [60% loading ], .3 [30% loading] in a day or working shift.

Step 2, Add up total usage and multiply with the usage factor, to arrive at the capacity usage.
Step 3, add about 10% to 15% of losses, due to leakage and other losses.

After listing all the air operated devices and equipments to be supplied by the air compressor, decide using charts, the pressure range and volume of air required by each and every devices and equipments.

These air compressor or compressors must maintain a minimum pressure at least equal the highest of these pressure ranges.

----- For Example:

If the highest pressure range required by any one device in a given group is 90 psi - 110 psi, a compressor or compressor must be able to supply the required volume, then the cut-in at not less than 90 psi and cut=out at 110 psi should be considered.

Exceptional:
Speed Controlled Air Compressor are used!

Then You have a rough idea of your plant compressed air requirement!

2. Existing Plant
2a. [Compressor always loading, that is cannot reach the required rated pressure]

Formula used:
P1V1 = P2V2

2b. [Compressor can off-load]

Formula used:
Air Consumption required = Vl/(u+l)

2c. Using Instruments
Energy Balance System

Positive Displacement Compressors-Screw

2008-12-26T00:29:00.000-08:00

Rotary Twin Screw Air Compressors

Description:
Rotary, helical screw, oil-injected, positive-displacement compressors are constant volume, variable pressure machines. They are available in a range from 25 cfm to 3000 cfm at pressure up to 600 psig in single, 2-stage & 3-stage designs.

USES
The most common uses of the rotary screw compressors are engine-driven portable compressors for mining, construction, and energy exploration.

And as electric-motor driven stationary compressors for industrial and mining application.

Rotary helical screw compressors of this types are characterized by compact, low vibration, simple foundation, broad pressure and capacity ranges, and long life with minimum maintenance.

They are used for pressure or vacuum services.

Design:
The single-stage design consists of a pair of rotor meshing in a one-piece, dual-bore cylinder. The male rotor, usually 4 helical lobes, spaced 90 degrees apart. The female rotor, usually has six corresponding helical grooves, spaced 60 degrees apart.

The rotor speed ratio is inversely proportional to the lobe-groove ratio. When the male rotor rotates at 3000 rpm, the female rotor would rotate ...... ....... rpm?

The male rotor can be directly driven, belt driven or gear driven by engine or electric motor. The female rotor is driven by the male rotor without metal-to-metal contact through the thin oil film developed between the rotors. Female rotor drive is possible in some design.

The rotors inter-mesh in the dual bores of a one piece cylinder (housing, or case). The cylinder provides air passages, oil injection holes, compression chamber, and discharge ports.

Each rotor is supported by rolling element bearings located at the ends of the rotor body. The bearings at one end, usually the discharge end, take the rotor axial thrust, carry radial loads, and provide for small axial running clearances necessary.

Bearings at the opposite end are floating bearings, which allow for uneven thermal expansion of the rotors and cylinder.

For 2 and 3 stages, the individual stages are designed to be similar to the single stage as far as the rotor configuration is concerned.

2 Styles

Two styles of multi-stage compressors are in common use;

Those axially mounted, in which the second stage is driven directly from the rear of the first stage.
And side or parallel mounted, in which the stages are each mounted directly on a gear housing and are independent of each other.

Some designs remove the oil and cool the air between stages in an intercooler, while others discharge the air and oil directly into the next stage.

Multi-stages
Multi-stages are used in compressors for either to improved efficiency or for higher pressure.

Performance
The overall efficiency of the unit depends almost entirely on the achievement of proper clearance in the rotors during manufacture. The normal manufacturer's warranty allows for plus +- minus of 3% variation in performance.

Discharge temperatures are much lower than in other types of compressors. Most manufacturers supply a thermostatic oil control valve to control the minimum discharge air temperature to avoid condensation in the reservoir or oil sump.

A 2-stage, 100n psig compressor improves performance by lowering the pressure differential across the leakage paths within the rotors [Blowhole] and end plates. The altitude [sea level vs mountain top] on which the compressor is located also has an effect upon performance.

The oi-injected screw machine is capable of operating on vacuum service and produces maximum vacuum equal to that of the 2-stage, double acting reciprocating machine. The oil flow are normally reduced because of lower mass flow.

The power consumption of the rotary-screw compressor during unloaded operation is normally higher than of reciprocating types. Recent developments by some manufacturers have led to systems in with the unloaded horsepower is 15% to 25% of loaded power.

This systems are normally used with electric-motor, constant-speed drives rather than engine-drives in which the engine speed can be reduced during unload, for reducing fuel consumption.

Application of the unit as a based load compressor is also recommended to avoid any disadvantage due to unloaded power coat.

source from CAGI handbook
edited version

Air Compressor Class

2008-12-25T23:07:00.000-08:00

Air Compressor Classification

2 types
Dynamic
Positive-displacement

Dynamic
Ejector
Centrifugal

Positive-displacement
Reciprocating
[Double Acting & Single Acting, Single-stage, Multiple-stage, Piston, Rocking Cam, Diaphragm]
Rotary
[Single Screw, Twin Screw, Scroll, Lobe, Liquid Ring]
********************************************************

Reciprocating
Double Acting
Single Acting

Double Acting
Double Acting, Single-stage, Reciprocating Piston Type

A group of Ingersoll Rand XLE Double Acting, 2-stage, Reciprocating Piston Compressors

Single Acting
Reciprocating Single Acting Piston Type

Rocking cam
Diaphragm

Single Acting piston type

Rotary:
Rotary Single Screw
Rotary Twin Screw
Rotary Scroll

Rotary Lobe
Rotary Water Ring

Rotary Compressor Coolant

2008-12-25T22:17:00.000-08:00

Rotary Compressor Coolant

Lubricant for Oil-Flooded Rotary Screw and Vane Air Compressors

Description:

The Rotary Compressor Coolant represents a “step-change” advance in lubricating oils specifically developed for oil flooded rotary screw and vane air compressors. They are premier quality products, highly recommended for both static and mobile plant with working temperatures up to 120 degree C.

The products are based on HVI paraffinic base oils, treated to reduce the polycyclic aromatic content, into which are blended additives to impart anti-oxidant, anti-wear, anti-corrosion, anti-foam and dispersions properties.

Extended field evaluations have demonstrated a vastly superior performance, to the extent that oil drain periods may be doubled. This effectively means an increase from the current maximum of 2000 hours to 4000 hours at a continuous maximum air discharge temperature of 100 degree C.
Combined with the extended life is a facility to keep the internal surfaces completely free from deposits whilst maintaining a steady differential pressure (dp) across the separator/coalescer. This means that premature blockage of separators/coalescers are eliminated.

MKT/JT/ABKD/104

Benefits:

Outstanding oxidation and thermal stability, which serves to extend the service life even with bulk oil temperatures up to 120 degree C.

Reduced maintenance cost resulting from the doubling of intervals between oil changes.

Excellent cleanness properties, eliminating the blockage of separators/coalescers.

Good protection against corrosion, extending the life of components in service.

Limited carry over of oil into the air stream, offering high quality process air.

Reduced risk of fire in the separator pack, due to the excellent oxidation and thermal stability of the oil.

Good anti-foam properties to suppress the tendency to foam excessively in service.

Good air release properties to minimize or avoid cavitations effects and increased compressibility.
Application:

The Rotary Compressor Coolant has been specifically developed to cater for the lubrication requirements of the complete spectrum of rotary screw and vane air compressors.

They are applicable to all types and sizes of rotary vane and screw air compressor whether oil flooded or oil injected, male or female drive, single or two stage configurations.

Although primarily designed for static industrial application, the coolant is equally applicable to the lubrication of air end in mobile plant configurations.

Oxidation Stability:

Oxidation can be considered the most important single property of oil for rotary compressors, since it is this, which primarily determines the useful life of the oil and its resistance to thickening and to the formation of carbonaceous deposits.

The excellent oxidation stability of the Rotary Compressor Coolant makes it possible to operate compressors continuously for long periods between oil changes, and at higher temperatures without the need to resort to highly price synthetic lubricants.

The IP 280 and IP 306 test results confirm the outstanding oxidation stability of the Rotary Compressor Coolant, in particular the very low ratios of sludge to TOP (total oxidation products) of 2.54% and 2.15% respectively against a permissible maximum of 40%.

Anti-foaming:

The ability of compressor oil to resist foaming is important, since malfunctioning of the compressor can occur if excessive amount of foam is allowed to form in the separator.

Tests have proved that the special additive combination in the Rotary Compressor Coolant reduces the tendency of the oil to foam in the separator.
Typical results in terms of IP 146 – the Foaming Characteristics of Lubricating Oil:

Sequence 1 10/NIL (Foaming Tendency/Foam Stability)
Sequence 2 Nil/NIL (Foaming Tendency/Foam Stability)
Sequence 3 20/NIL (Foaming Tendency/Foam Stability)

Protection Against Corrosion:

The occasional presence of water in oil-flooded compressor systems is possible, so it is important that the oil gives protection against corrosion. In addition to the associated mechanical problems, fine particles of rust dispersed in the oil will reduce the oxidation stability of the oil considerably and will also adversely affect its air release properties.

The Rotary Compressor Coolant have excellent corrosion inhibition properties and give a ‘no-rust’ result against IP 135 B – Rust Preventing Characteristics of Steam Turbine Oil in the presence of synthetic salt water.

Oil Drain Periods:
For many years, 2000 hours has been generally accepted as an extended oil drain period for rotary vane and screw air compressor maintenance schedules and service requirements.

It is recognised that operating temperature has a fundamental effect upon the rate of oil degradation through oxidation.

With our Rotary Compressor Coolant incorporating the most up to date oil technology, 4000 hours oil change may now be accepted as the norm, even when operating at a continuous maximum discharge air temperature of 100 degree C.

Internal Cleanliness:

Coupled with the long life capability is the ability to maintain excellent internal surface cleanliness in service. This is particularly relevant to the function and operation of the separator/coalescer. Design varies according to the manufacturer; nominal filtration of ½ micron is typical for this application.

Blockage of these elements with what was thought to be polymerised products of oxidation has been endemic, in some cases after only 100/200 hours of operation.

In a test using Rotary Compressor Coolant, the separator element from a Compair-Broomwade Ltd trial machine was removed and inspected after 8400 hours of intermittent operation, simulating typical in-service conditions.The metal and fibreglass element were in ‘as new’ condition, and the dp (differential pressure) across the separator was recorded at a constant 2.5 psi over the whole evaluation.
The screw element from the trail assembly was also inspected and was found to be in excellent condition.

Sealing:

The Rotary Compressor Coolant is suitable for use in conjunction with all commonly used sealing materials.

Change-over Procedure:

Changeover is relatively straightforward:
1. The original charge should be fully drained and disposed of.
2. If the oil system has shown evidence of contamination or is otherwise less than satisfactory, a flushing charge may be appropriate.
3. Assuming item (2) not to apply, the system may be filled to the correct level and run in the normal way.
4. Assuming item (2) to be necessary, the flushing charge should be introduced and run up to normal working temperature for, say, 4 hours. It should then be fully drained, preferably at 50 degree C or above and then disposed of.
5. The working charge should then be introduced to the normal working level and the machine restarted.

Health And Safety:
The Rotary Compressor coolant is unlikely to present any significant health or safety hazard when properly used in the recommended application and good standards of industrial and personal hygiene are maintained.

See separate Safety Data Sheet.

MKT/JT/ABKD/104

Air Filters maintenance

2008-12-25T05:17:00.001-08:00

Air Filters

The 1st place that dirt get into the compressor is via the intake. To prevent dirt from getting inside is to install a appropriate size air filters.

Some typical use air compressor filter elements.

They are made of filter grade filter paper.

Filter maintenance 1
Visual inspection

Remove of filter dust trapped at cover through centrifugal flow of air inside the filter housing.

Low air pressure jet to clean air filter

Choke up air filter

Air filter need to replace.

Filtration

2008-12-25T05:08:00.000-08:00

FILTERS

The purpose of FILTERS --- according to general definition:
Is to keep contamination transported in the air and oil out of the compressors.

Compressors together with gearboxes, fluid-power system (hydraulic & pneumatic), internal combustion engines and industrial machinery have a common problem:

"Wherever moving parts contact or mesh with one another, FRICTION results."

This friction has to be reduced. to this end, a suitable, mineral or synthetic oil, is used to provide a sliding film between the moving or rotating parts of the machines. This is only possible if the lubricating oil stay clean and remain clean. If foreign particles, even if they are microscopic in size, are transported with it.

Such particles can reach the moving or rotating parts inside the compressor in the form of sand or dust in the oil or air intake.

Whenever friction occurs, fine metallic abrasives are created, found it's way in the oil, creating even more metallic particles to get into the compressor oil or coolant.

Critical areas within the compressors are the compressor case (housing), screw rotors, seals, bearings, gears, valves etc. In addition, compression does not occur without leaving residues. If this is nor filtered out, the foreign particles acts as an abrassive mass, which can considerably accelerate wear on the moving parts.

Also, dirt particles when in excessively high concentrations though they are not as hard, can be dangerous for compressor. It can damage the compressor due to inadequate lubrication and cooling.

A well-maintained and effective oil filtration system along with good air filtering, is the best guarantee of long compressor life.
Main-flow filters and air inlet filters are usually designed for 25 micron particles filtration and 10 micron for bearings

Positive Displacement Compressors-Vane 4

2008-12-25T03:19:00.000-08:00

Built-in Safety System

The minimum pressure valve (MPV) has a secondary purpose, that is, acting as a non-return valve when the compressor stops or off-load.

This is to prevent the line air pressure is not lost by reverse flow from the air system back to atmosphere via the compressor.

When the compressor stops, the intake valve is automatically closed, and the internal pressure within the compressor is gradually reduced or vent out to the air intake. This is achieves by mechanically, hydraulically or electrical solenoid valve.

This is to prevent hydraulic locking and possible damage when the compressor restarted.
The compressor will start with a light load and low starting current.

Safety Devices
Safety devices are install to protect the compressor against malfunction due to high air oil temperature, lack of oil, lack of cooling air or water or abnormal electrical supply.

Monitoring Devices
Monitoring devices are also installed, Certain design have more components and some with the minimum number. Signals when filters are to be cleaned or replace, Separator differential pressure, minimum & maximum pressure, oil & air end bearing temperature readings, water separator conditions, hour meter, motor conditions to indicate maintenance frequency.

Compressors with constant running control, start-stop control, manual dual control, automatic dual control, lead-lag operation for multiple compressors application.

Run-on timers for keeping the compressors running to minimize condensation during short demand periods, run-on timers to shut down compressors when there is no demand for air, are offered by various manufacturers.

They are compact, free from vibration, and with low noise levels. The air delivered is cool, clean, and free from pressure pulsation, and in some cases air receiver is not necessary. They can be mounted anywhere including immediate work areas.

Panels may be included to reduce noise level, panels for outdoor usage may also be order.

Positive Displacement Compressors-Vane 3

2008-12-25T01:25:00.000-08:00

Operation

The lubricating-cooling system consist of oil filter, minimum pressure valve (MPV), a heat exchanger.

Thermovalve
And in some designs (usually the bigger horsepower units), temperature control (regulating) valve is used to maintain a relatively constant temperature regardless of compressor load.

Oil Circulation
The use of Compressor lubrication is very important! and cannot be denial? Especially the grade and type of lubricant use.

Oil circulation is usually provided by the pressure-differential system. Circulation in the pressure-differential system is achieved by using higher-pressure air to generate the oil flow. A preset minimum pressure valve (MPV), usually about 80 psi, allows the quick pressure build up in the oil sump before the MPV opens to discharge compressed air to the air system.

MPV
The pressure differential between the fully compressed air, and the pressure within the cell as it passes or rotates. The pressure differences thus created, caused the oil to be injected via orifices into all moving parts, including the rotor bearings located in the end covers of the stator..

In all and every cases, the compressed air pressure is relieved automatically from the discharge side of the compressor during shutdown.

Therefore, with this design and operation, there will be oil presence in the compressed air. It is not desirable to have oil in the compressed air, and it is necessary to remove the oil before it is send to the air system.

Oil Separation
Therefore; as air and oil mixture passes from the compression chamber, the oil, which is heavier, is mechanically separated by direction and velocity changes, or use of baffles, or of both, and allowed to drain back into the oil chamber or oil sump for recirculation.

Relatively clean air leaves the sump and enters the separator, where most of the remaining oil is removed by coalescence called air/oil separator/s.

The coalescence (separating media) are ceramic tubes or combination of mesh & fibre glass (Boros Silicate).

The Scavenging Line
The separated oil (residue oil) drains from the coalescing media to collection well for subsequent return via a combination of orifice and check valve to the intake side of the compressor.

Oil Carryover
The amount of oil carried over is less than 5 to 1 ppm of air measured by weight.
Air losses through the oil return (scavenging) line is controlled by an orifice.
The resulting pressure drop through the separator should be approximately 1 to 3 psig, when new. Should change or replace the separator when the pressure difference is at or more than 15 psig.

Heat Exchanger
Air-cooled or water-cooled heat exchanger are used for the oil. The air-cooled heat exchanger is of radiator type, with a cooling fan to provide air circulation. The water-cooled is shell & tube type, and need an external water circulation and cooling system.

Oil circulation at start-up
On start-up, oil bypass the heat exchanger (cooler) and circulates through the compressor and sump with cooling. This provide rapid oil supply & heating on start-up. When correct oil temperature is reached, the temperature regulator modulates the oil flow to maintain the optimum temperature.

Positive Displacement Compressors-Vane 2

2008-12-23T22:58:00.001-08:00

Design

Air Compression between sliding vanes is basically a simple concepts.

Compression takes place when the volume of the spaces between the sliding vanes in a rotor is reduces as the rotor turns or rotate within an eccentric cylinder (housing).

The distinguishing features of these type of rotary sliding vane compressors is the injection of liberal quantity of oil directly into the compression chambers:
1. To seal the cells,
2. Provide lubrication,
3. Cooling,
and
4. to absorb the heat of compression

Constructions and designs varies with different manufacturers, but the principles of operation and control are similar.

The rotor has 6 to 8 longitudinal slots in which, vanes slide freely, move outward by centrifugal force against the cylinder wall of the stator.

As the rotor rotates, each vane sets pass the inlet (Suction) port to form a cell (Chamber), between it and the preceding vane sets. The air, that is trapped is compressed as volume of the cell decrease until the leading vane of the cell pass the outlet (discharge) port.

With rotation counter-clockwise, the volume between the vanes, the rotor, and the stator is increasing between the inlet port, at right, and top.

Consequently, partial vacuum is created, cause it to sucks in more fresh air from atmosphere in through the inlet port. The volume then decreases as the cell approaches the outlet post at top left, causing the air pressure to rise. Air is not leak back around the rotor, because it is sealed between the rotor and its blades, concentric bore in the stator and compressor oil.

These positive-displacement have a fixed compression ratio for any given model. Ratios up to 10:1 can be used to compressed air in a single stage.

An important factor in obtaining high efficiency is the controlled oil injection into the compression chamber.

Oil is injected for:
1. sealing each cell from its' neighbour,
2. seal between the high=pressure and partial-vacuum conditions within the cycle,
3. cool the air been compressed,
4. Lubrication.

Positive Displacement Compressors-Vane 1

2008-12-23T22:05:00.000-08:00

Positive-displacement Compressors
Vane

Vane and Screw are classified under the main group know as Positive-displacement compressors.

According to Compressed Air and Gas Handbook:
A positive-displacement compressor is a machine in which, a quantity of air or gas occupies a space that is mechanically reduced, resulting in a corresponding increase in pressure.

It should be realised that during the last 20 over years, there has been a significant swing from reciprocating to packaged, rotary air compressors.

From Compressed Air and Gas Handbook,
The oil-injected, sliding vane rotary compressor was introduced as portable, engine-driven compressor way back in year 1950.

Actually, it was produced in Italy, way back in the year 1923 by a company now know as Pneumofore.

Shortly thereafter, it was applied as stationary industrial compressor with electric motor drive in 1956. It has since been incorporated into diesel-engine-packages. Lately, especially the smaller and more compact designs have been incorporated into the original equipment of many manufacturers.

Since, the introduction of these compressors into the industrial market, many improvements have been made, thus, providing a reliable compressor package.

The compressor is normally furnished as an engineering package, so installation is simplified.

These design minimize maintenance and is free from vibration problems, and its compact size eliminates the need for extensive foundations.

It can be water-cooled or air-cooled packages.

Motor Shaft

2008-12-23T21:43:00.000-08:00

Main Motor Shaft Failure

Broken Main Motor Rotor Shaft of An Ingersoll Rand Model XF100.

The other section of the Broken Main Motor Rotor Shaft.

We can replace the Rotor of that shaft without purchasing new MOTOR!
It is in operation for more than a year now. This company operate 24 hours a day for 365 days.

Blow Hole

2008-12-23T21:25:00.000-08:00

"BLOW HOLE"

Back pressure leakage that happens to ALL screw compressors called the "Blow Hole"

The Blow Hole will get bigger over time.
Cause by wear and tear of bearings.

Therefore;
Overhaul and replacement of bearings is a must! & cannot be avoid?

Typical RESULTS could be;
* Air-End will operate at hotter and higher temperature!
* FAD will be lesser and lesser!
* Oil & Air leak all over!
* Sometimes humming sound
* Higher Current consumption

Rotary Air Compressor Selection Guide

2008-12-15T00:57:00.001-08:00

Rotary Air Compressor Selection Guide

Ingersoll Rand M Range Rotary Screw Air Compressors' Air End Overhaul Manual --- FREE?
with purchase above US$80.00 from us, only pay for Shipping & Postage charge of US$15.00.

--------------------------------------------

NOTE:
We accept Credit Card via Paypal

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Design for personals involve in selecting and maintaining the Most Popular Rotary Air Compressors.
*** Most Popular do not mean the BEST! ***

PDF format.
FREE with purchase of "Screw Compressors" each, we pay for shipping charges.

Order NOW!
Nikaya (M) Sdn. Bhd.
52, Jalan Bagan 1, Taman Bagan, 13400 Butterworth, Penang, Malaysia.

A guide to help you choose the most suitable Rotary for your uses.

Scope;
The scope of the rotary positive-displacement compressor section shall include:
Rotary positive-displacement compressors may be oil-free, forced feed lubricated or liquid injected, including but not limited to; sliding vane, lobe type, scroll, and helical screw.

Content:

Oil Injected Rotary Screw Compressors
Oil Free Rotary Screw Compressors
Oil Injected Rotary Single Screw Compressors
Oil Injected Rotary Sliding Vane Compressors
Scroll Compressors
PTO Compressors
Capacity Controls for Rotary Displacement Type Air Compressors
Instrumentation & Accessories for Rotary Displacement Type Compressors
Glossary of Terms

Screw Compressors

2008-12-15T00:50:00.000-08:00

Rotary Screw Air Compressors

A story about Rotary Screw Air Compressors.

With lots of diagrams & pictures. "Picture can speak more than a thousand words"

Design for Maintenance personals, and those interested to learn about Screw Air Compressors

Operation & Maintenance.

pdf format
US$67.00 each, We will pay the shipping charges.
and get Rotary Air Compressor Selection Guide for FREE!

Order NOW!
Nikaya (M) Sdn. Bhd.
10, Tingkat Siakap 13, Seberang Jaya, 13700 Perai, Penang, Malaysia.

-----------------------------------------
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We accept Credit Card via Paypal.
Or
Bank-in to my Account.
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Content:

Air End Failure 7 - Shaft Seal

2008-12-13T18:13:00.001-08:00

Typical Air End Failure:

Shaft Seal Problem

EcoAir 75Kw

Shaft seals
Lip seals, Wear sleeve & Mechanical seals
(Viton & Teflon)

Air End Failure 6 - Lubrication

2008-12-13T18:06:00.001-08:00

Typical Air End Failure:

Lubrication Problem

1. Vanishing.

Vanish due wrong type of coolant and/or mixing of brands of coolant.

2. Lack of Lubrication

Air End Failure 5 -Bearing

2008-12-13T18:03:00.000-08:00

Typical Air End Failure:

Bearing Failure

A Failed Air End Bearing type QJ

Air End Failure 4 -Filtration

2008-12-13T17:55:00.000-08:00

Typical Air End Failure:

Filtration (Air and/or Oil)

CompAir 6050N

Ingersoll Rand SSR MH75

Foreign Particles
Atlas Cpoco GA37

Ingersoll Rand SSR ML22

Air End Failure 3 - Normal Bearing Wear

2008-12-13T17:42:00.000-08:00

Normal Bearing Wear

Big Size Air End (Bigger bearings) versus Small Size Air End ( much smaller bearing is used).
This one determinant factors on the Price of Compressors.

Just imagine.
Low speed (1500 RPM) screw and High speed (9800 RPM) screw that produce the same air delivery.
The big and low RPM screw will have a much longer bearings change intervals.

1. Thrust Bearing Load

2. Temperature Change

3. Design Challenges

Air End Failure 2 - Drive Shaft

2008-12-13T17:21:00.001-08:00

Typical Air End Failure:

Drive Shaft related failure.
Shaft after repair,

Hitachi Twin Screw Pinion Shaft.

1. Broken drive shaft.

2. Worn out Shaft,
Drive End bearing seat.

Air End Failure 1 - Drive Gear

2008-12-13T17:12:00.001-08:00

Typical Air End Failure:
Drive Gears related.

Sample of SSR ML37, Gear mesh on motor drive!

Metal chips effective the screw profile.
Internal leakage (e.g. blowhole) is increase causing compressing efficiency drop.

Rotor Shaft Failure & Repair

2008-12-12T20:58:00.000-08:00

Rotor Shaft Failure & Repair

Note:
The worn out bearing seat on pinion shaft.
Cause local vibration to compressor package!

Hitachi Twin Screw Compressors

75kW Compressor

1. If Rotor Shaft is Broken.
2. Worn out shaft, usually on DE bearing seat.

1. Broken Rotor Shaft

Replaceable Rotor Shafts

Replaced Rotor shaft

Group Photo

2. Worn out DE side of bearing seat

After Metalizing and machine to Rotor shaft

If your faced any of the above problems, We have the solution for you .
Just an e-mail or a phone call away.

Act NOW
Another Sample

Sample of Atlas Copco GA75 Rotor Shaft failure at gear box:
Note the fail Drive gear & rotor shaft!

A close-up picture!

Peel of part of drive-end Rotor Shaft near key way?

Finally, the Drive shaft Shaft -- Exposed!

Challenges in Screw Design

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Why performance Twin Screw Compressor will drop over a period of time. and by overhauling will not improve it's performance (efficiency)?

Note:
The clearances, Between the male and female rotors.
The clearances, Between the rotors and the Housing (Compressor case).
The Clearances are seal by using it's compressor oil (coolant), therefore, it is very IMPORTANT to use the right quality of coolant.

At this moment in time, We in Malaysia, have many challenges to repair the sealing strips, and to make the clearances between the screws, as well as screw and the housing (Compressor Case) clearance back to original position.

Why we need to overhaul?
Here are some reasons.

"Blow Hole"

Back pressure leakage that happens to ALL SCREW Compressors called the " BLOW HOLE"

We name it as Blowhole; the compressed air leakage back to the inlet (Suction), from high pressure side at far end.
Due to the pressure difference between the two extreme end.

The "Blow Hole" will get Bigger over time, cause by the wear and tear of the bearings.
As such, Overhaul and replacement of Air-End bearings are unavoidable.

RESULTS from "Blow Hole":
* Air-End will get hotter and the compressor trip
* Free Air Delivery will be lesser & lesser
* Oil & Air leaking all over

The Higher discharge pressure will cause a thrust force between screw rotors and end plate, and is transmitted or pick up by the bearings.

Principle of Operation

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Typical Twin Screw Air Compressors

3 = Suction (Inlet Valve is located)
2 = Female Screw (Usually driven)
1 = Male Screw ( Usually Driver)
4 = Discharge port (Outlet)

Note:
The position of the dark strip of Compressed Air, as it moves inward (lower side of screws assembly and the housing) to the other end, push in by the male screw (Piston) along the female flutes (cylinders).

Inlet Valve

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Inlet Valve Pneumatic cylinder
For Ingersoll Rand Screw Air Compressors

Repair Kits

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Repair Kit for use on Ingersoll Rand Air Compressors

Minimum Pressure Valve Operation

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Note:
The various position (Inside) of minimum pressure valve, during difference phases of compressor operations.

Compressed Air Piping Installation

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We provide compressed air Piping Design & Installation.

Instructor

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Instructor, Trainer & Life Coach.

We provide training services.

I have more than 24 years working experiences in many major brands of air compressor in Malaysia. Of which 7.5 year with Ingersoll Rand Master distributor in Malaysia, namely Ingersoll-Jati (M) S/B.
2 years in training and coaching to other independent air compressor repairers in Malaysia.

Screw Ingersoll Rand Compressor Air End

2008-12-02T23:45:00.001-08:00

Purchase the Air End we will give YOU a FREE copy of Air End Overhaul Manual!

Come with a FREE copy to Overhaul Manual for this type of Air End (SSR)

We have used and overhaul screw compressors' air end for sale ex-Buttewworth, Penang, Malaysia.

The two pcs front roller bearings, we have replace to brass cage type.

Suitable for Ingersoll Rand compressor,
Model: ML75, MH75, ML55, MH55.

Ex-Stock = only 1 unit

Another view of the same air end

To view, contact me at 6012-4982163
Location:
Nikaya (M) Sdn. Bhd.
52, Jalan Bagan 1, Taman Bagan, 13400 Butterworth, Penang, Malaysia.

New & Used Screw Compressor Parts

2008-12-02T23:45:00.000-08:00

New & Used Screw Air Compressor Parts

Ingersoll Rand SSR M11 to M30 Screw Air End, Belt driven version.

View one.

This Manual FREE with purchased of Air End from us!

One unit only (Belt Drive)
Another View.

Another View

We have used
and
overhauled
screw compressors' air end for
sale
ex-Buttewworth, Penang, Malaysia.

Any Used Air End Purchase, we will give FREE copy of Air End Overhaul manual.

Ingersoll Rand XF models (Control voltage = 110Vac)

Address:
Nikaya (M) Sdn. Bhd.
52, Jalan Bagan 1, Taman Bagan, 13400 Butterworth, Penang, Malaysia.